Apparatus for making metallic surfacing sheets



, Aug. 24, 1943.

D. A. JOHNSTON APPARATUS FOR MAKING METALLIC SURFACING SHEETS Filed Sept. 14, 1959 3 Sheets-Sheet l DwlqHTAfl'oHmsToN 1943- D. A. JOHNSTON 2,327,844

APPARATUS FOR MAKING METALLIC SURFACING SHEETS Filed Sept. 14, 1939 3 Sheets-Sheet 2 DWI qHTA JoHNsToN Mow,

Aug. 24, 1943.

D. A. JOHNSTON 2,327,844 APPARATUS FOR MAKING METALLIC SURFACING SHEETS Filed Sept. 14, 1939 s Sheets-Sheet 5 DWIGHT A. JO NSTON Patented Aug. 24, 1943 tzszisi f APPARATUS FOR MAKING METALLIC SUBFAGING SHEETS Dwight A..Jolmston, Youngstown, Ohio, assignor jto .McKay Machine Company, Youngstown, Ohio, a corporationcf Ohio a Q Application September 14, 1939, Serial No; 294,902

T Germs. (01. 153-77 I This inventionrelates to a' method and apparatusfor forming metallic'surfacing sheets and more particularly to an improved method aind apparatus for embossing the sheetistockwith the required channelsgor corrugations in.axtvery"ac' curate and economical manner. I The metallic sheet stock'normally used in the manufacture of surfacing units'for roof and wall use is of relatively thin gauge and as such has little resistance to-twisting or torsional deformation and it has therefore been found desirable to provide the sheets withv'corrugations or channels for the primary purposeofstrengthening the individual units. In practice, such corrugation is usually placed longitudinally .oflthe sheets in laterally, spaced relation along each: side edge of the sheets and in certainlproducts. a longitudinal corrugation is also positioned centrally of the sheets. 1 i r Aside from th e str'engthening utility of: the corrugations along the side edges of the sheets, consideration has also been given to theuse of the corrugations as a seal'to prevent the lateral passage of Water by capillary movement or th erwise between the laterally overlapped side edges of the respective sheets onto the base surface below the metal sheets. This is accomplished by .so designing thetransverse contour of l the side corrugations that thecorrugation or channel along-the side of one sheetwill nest into the corrugation or channel along the adjacentside of an overlappedsheet in such manner that'a tight joint is provided and agprotected trough extending longitudinally of the seam is formed to carry any water which may have gotten between the "overlapped sheets down to the gutter of the building. I

To strengthen the sheets along their transverse directions andto provide means to prevent Water from passing .upwardlyl-between "longitudi nally overlapped sheetsiby scapillary attraction and otherwise, it isnow proposed to incorporate in each sheet a transverse'corrugation adjacent the lower edge of-the sheet; and extending the full distance between the corrugations which extend longitudinally alongtheside. edges. of the corrugations presents considerable difficulty, 'particularly. when it is desired to complete themanufactureof the surfacing units by an economical continuous process, since the interval between the end of the sheet and the transverse corrugation must'be accurately maintained to insure the accurate interfitting of the units when laid upon the'wall or roof and since the extentpf and variation in the length of the sheetsin'on" mally prevents 'the use of a conventional die rollingstand; i

It is accordingly the primary object of the invention to provide. an improved apparatus %for' forming transverse corrugations adjacent one end of metallic sheets previously corrugated; longitu dinally whereby the units may be manufactured with precise accuracy and with'economy." if

A moreJspecific object of the invention is the provision lof an" improved apparatus for forming transverse corrugations adjacent 'one end of corrugations. are accurately positioned with respect tothe' adjacent end of the sheets'and the longitudinal corrugations. 1 This is accomplished; inaccordance With the present invention, by providing a :pair of. mandrels, onep'ositioned' below the path" of t'ravelof the sheets and the other'po sitionedthereabove, each provided with roll rings freely rotatable thereon and-arrangedin sets-to provide a rigid guiding and'retaining pass which is continuously eiiective duringthe entire trav erse of the sheets and during the transverse cor= rugating' operation'whichtakes place whilefthe' sheets are so retained and guided. 'The' means employed to corrugate the sheetstransvers'ely consistsof the die segments orrolls carried by the mandrels-betweenthe ring sets and rotatable from an inoperative position through an are including theplaneof the axes of the mandrels to effect the embossing or corrugating operationduring the. travel. of the st'ocl; sheets through the pass;

Yet another object of the'invention is the pro vision in a continuous production process of improved means for initiating rotative movement of a set of die rolls whose function is to emboss or corrugatesheet material coiningtherebetween and for'applyin'g sufficient power for the rotation of saidrolls to insure the performance of weenboss'ing' or corrugatingoperation without damage to the material being worked on. I

A still further object of the invention is the immediatelyabove of an improved arrangementfor the synchronization of the rotative speed of the dies and the speed of travel of the stock through the pass whereby the desired deformation of the stock being worked on may be accomplished without marring the surface of the stock.

These and other objects and advantages of the invention will become apparent from a consideration of the following detailed specification and the accompanying drawings wherein there is specifically disclosed a preferred embodiment of the invention.

In the drawings:

Figure 1 is a side View of an. apparatus constructed in accordance with theprinciples of the invention and capable of carrying out the method disclosed herein.

Figure 2 is a transverse sectional view of the apparatus of Figure 1 taken along the line II--II of Figure 1;

Figure 3 is an enlarged side view of a portion of the apparatus of Figure 1 with ce'rtainoutboard housings removed; and

'Figure 4 is a sectional view through the trans verse corruga'ting rolls and guides mounted thereon. I

The apparatus of the invention. consists gen-' erally of a series of stands offorming rolls, indicated generally by the referencenumeral Ill, mounted on the base I I, a cross-corrugating roll stand l2 and a pull out roll stand It also mounted on the base H. e In accordance with usual practice, the stands I0, which may varyin number.

from a relatively few to i 2 or more depending on the product being produced. are each provided with an upper and lower forming roll having complementary interengaging annular dies of progressively increasing depth whereby the metal sheet material is provided with longitudinally ex-. corrugations as the.

tending deformat ons or sheets pass through the forming mill constituted by the stands. A bottom supporting roll i l and side guiding rolls l5 are provided to guide the sheets into the first stand of the mill.

Vince of this invention to provide the sheets with accurately positioned transverse deformations or.

corrugations as the sheets issue from the primary forming mill without interf r ng with. the speed.

of travel of the sheets or the operation of the mill. For the accomplishment of this object, up-

and outboard housings i8 and 19, respectively,

and one of the rolls. as it, is provided with a die of the forming mill are each provided with an-. nular dies adjacent their ends and also centrally. thereof whereby the sheets passing through the mill willbe provided with longitudinally extending deformations extending along either'side edge of each sheet and with the longitudinally extend-1 ing rib alongthe center. of the sheet; As stated above, the transverse corrugations in the sheets extend-substantially the entireinterval between grooves 28 intheir mid-sections.

the longitudinal corrugations and therefore the rolls [5 and IT, as specifically disclosed, are each provided with two segmental die portions spaced tween said rolls may be controlled in accordance with usual practice by rotation of the hold-down screws E25. Shafts 22 and 23 are geared together by the spur gears 26 keyed to the shafts and intermeshing with each other, a indicated in the drawings. Rolls l6 and H are each provided with annular recesses 2! at their ends and annular Fitting within the recessesv 2! of the upper roll is are the annular rings 30 having peripheral die surfaces cor"- responding to the contours of the upper surfaces of the side corrugations formed in the sheetsby the roll stands I 0. Rotatably mounted in the annular recesses 21 in'the lower roll H are the an-' 1. nular rings 3| having peripheral die surfaces complementary to the outer surfaces of the rings 30 and conforming to the contour of the lower surface of the side corrugations rolled into sheets by the stands iii.v Likewise, annular rings 33 and 34, having complementary peripheral die surfaces forming a pass to guide the central rib formed in the sheets, are mountedin the annular grooves 28provided in the upper and lower'rolls I6: and I1, respectively. r The rings 30, 3l,-33 and 34 are each freely rotatable in their respective recesses and with respect to the rolls with which they are associated, suitable bushings 36 and 31 being pro vided to reduce the friction between the rings and the rolls. Rolls [Sand H are so keyed togetherjby the gears 26 that the complementary dies carried thereby will be in their'proper operative relative positions as the dies move through the plane of the axes of rotation of the rolls as the-rolls are rotated. Extending outwardly from the face of the upper roll lfi'and substantially co-exten sive with thedie 20 is the key 39 rigidly carried by and. movable withthe upper roll 16} The key 39 is positioned adjacent a circumferential end of the die segment 20 and its function is to provide an abutment for engagement by th leading ends of the sheets, thereby providing means for the initial rotation of the rolls as the sheets enter the transverse deforming pass. As shown in Fig- 5 ure 3, the interval between the key 39 and the per and lower rolls !5 and H. respectively, are: mounted for rotational movement about parallel axes lying in a plane normal to the direction of: movement of the sheets as they issuefrom the. mill. 'R0lls l6 and !'l are journalled' in inboard adjacent'circumferential ends of the dies 20 and 2| is such that when the rolls are in their initial starting positions the projections of the dieslfl and 2| will lie justoutwardly of the path of travel of the sheets'through the pass.

Keyed to'the'lowershaft 23 is a sprocket 40' vrangement of the parts is such that actuation of the cylinder 42 rotates the rolls 16 and I! in such direction from their initial starting position-that the die segments 20 and 2| will be caused-to move beyond the plane of the axes of rotation of said rolls along withthe sheet stock passing there-' between to effect the transverse deformation in the sheet stock. The spring 43 returns the rolls l to theirinitial starting positions upon the With'--' drawal of air. pressureto the cylinder.

Die segment 2I on roll I! isprovided with'an= end shoulder 45; adapted to engage a fixed abutment 46- to limit 't-he return rotational movement of'the shaftsand rollst}, The various parts so relatively positioned that whentheabutment 46 is engaged by theshoulder; 4 5,; the key 39 is positioned immediately beyond the plane of the axes of theroll shafts-22 and Z3. 'The circumferential interval betweenthe key 39 and the dies 20 and 2 is predetermined in" accordance with the dimension requirements-of the product being manufactured and the arrangement insures the maintenance of the properinterval between the ends of the sheets and the transverse-corrugation during themanufactureof the sheets. v I

Between the last pass of the forming mill and the pass formed by the rolls lfi and I! are the rotatably mounted on these rolls. Upper guide forked or slotted to' receive a roller or skid 54' normally biased to upper position in the path of travel of the sheets between the guides and operatively connected withthe normally open switch 55. Switch 55is conveniently supported on the standard 52.

Extending up through the abutment 46, which may also be an integral part of the standard 52,

is the plunger '56 suitablyguided in the standard 52 and biased to upper position by the spring 57. As indicated in Figure, 3 of the drawings, the upper end of the plunger 56 is adapted to engage the shoulder 4-5 of the diesegment 2!.

The lower end of the plunger 56 is operatively connected with the switch Eilandthe arrange-- ment is such that when the plunger is inits-lower position,.as shown in Figure 3 vof the'drawings, the switch 58 will be open'but when the plunger is moved to its upper position by the spring-iil'upon movement of the shoulder 45 away from the: abutment 46 the "switch 58 will be closed. r i

Air issupplied to thevcylinder 42 from'a suita- 1 ble source through conduit 6B, three way valve-6 I.

and conduit 62 interconnecting the valve. and the cylinder. Valve (BI is operatedbysolenoid 63, the energizing circuitfor which includes a suitable current source .64 and the switches and B in series. -One way metering valve $5 is interposed in the conduit 62 to adiustably meter the flow of air into one end of the, cylinder 42. Valve 66 places no restriction on the flow of the air outwardly from the said end of thecylinder 42, A similar oneway metering valve 5'! connects the other end of the cylinder 42 with the atmosphere, the arrangement being such that an unrestricted outward flow of air may take place while the air coming into the said other end of the cylinder may be controllably metered.

Positioned outwardly of the cross-corrugating stand I2 is the pull-out stand !3 having a pair of driven pinch rolls 59 which are operative to engage the sheets as they issue from the crosscorrugating pass and to pull the sheets clear of the machine Interposed between the crosscorrugating stand l2 and the pull-out stand i8 are straightening rolls H1 suitably and adjustably mounted by the adjacent housings or the base H.

The operation of the apparatusjdescribed,

above is as follows: 7 c

Duringnormal operation of the machines the rolls of the forming stands l0 and. of the pull. out stand I 3 are continuously driven at a con; stant rate of speed and as the successive sheets are fed into the machine past the guide rolls I 4-45 the rolls of the stands will engage the sheets and ion in the longitudinal deformations, as explained above; The sheets, on issuing from the last forming stand, "will pass between the guides 49 and 50 and into the pass between shafts 22 and 23 of the orbss-corrugating stand.

As a sheetreaches the position of: the roller54 the roller will be depressed and switch 55' closed. The sheet on entering the pass aforesaid will engage the key 39 and impart initial rotational movement to'the shafts 22 and 231 Initial movement of the lower shaft'23 will result in move ment of 'theshoulder 450i the die segment 2! away from the abutment 46 and the upper end of the plunger '56,allowing the plunger to move upwardly andthe switch EB'to close. Switches. 55 and fiflwill now both be closedand the sole- 25 noid 63 energized, Energization of the sclenoidactu ates valve iii to interconnect conduit Eitwith conduit 62, thereby allowing air under pressure to flow to the upper end of cylinder 42, whichresults in downward movement ofthe piston in 39 the cylinder and movement of the chain 4.l. The

die segments 20 and 2 I, being keyed to the shafts' 22 and 23, will now be rotated into engagement with the sheet, between the shafts to, effect the transverse deformation in the sheet and will moove past the plane of the axes of the shaft to a position clear of the path of movement of the sheet. By adjustment of the valve 66 the speed of rotation of the die segments rnay'he correlat ed'with thespeed of movement of the sheet, I operation of 1 the 40 thereby insuring smooth process. As the trailing end of the sheet aforesaid pass-' es over the roller 54' theroller will be moved to' upper position by its biasing means, thereby opening theswitch 55. Thefsolenoid energizing circuit is thus opened and the valve ill will be.

moved to opposite position closing conduit Bil and interconnecting conduit 62 with an outlet" to the atmosphere ll, The air above the piston in cylinder'42 isnow free to move out through conduit 52 and outlet 1.! and the spring its, con-h nected with the other end of the chain 4| and previously tensioned by actuation of cylinder 42,

To allow thesheet to clearipthe pass between theshafts 22'and23 before. the dies '20"jand. 2| are moved, back through the pass, valve 61 is employed to meter the flow of air into the lower end of the cylinder 42. By adjustment of the valve 6'! the rate of return movement of the dies may be controlled.

It should now be apparent that I have provided an improved method and apparatus for carrying out the method which is capable of accomplishing the objects initially set out. The employment of the guide rings 39-34 on the rolls carrying the die segments 2!] and 2| insures the accurate lateral alignment of the transverse corrugations and the employment of the key 39 insures the accurate longitudinal spacing of the corrugations. By employing positive power driving means forthe segmental dies 20 and 2! during their working period the transverse corrugawill rotate the die segments Ziiand 2I'back to-" sheet and without undue marring of the surfaces of the sheet. Moreover, the transvers corrugating is accomplished without interfering with the movement of the sheets through the machine or the operation of the forming mill thereof and the machine and process is capable of operation at high productive speeds.

It should be understood that various modifications may be made in the machine, organization and structure without departing from the spirit or scope of the invention. For example, the shafts carrying the die segments may be driven by means other than that specifically disclosed and instead of returning the dies to their ori-ginal position by reverse movement of the parts an arrangement may be utilized whereby the dies would move only in one direction. For example. the lower shaft 23 may be initially moved through 180 counter-clockwise, as viewed in Figure3, to effect the transverse deformation and asthe trailing end of a particular sheet clears the pass between the shafts 22 and 23 the shaft 23 may continue .to counter-clockwise rotation through another 180 back to its original starting position, as shown in the figure. This may be accomplished by a suitably geared single revolutionv clutch or other equivalent means well known in the art and byemploying suitably retractible limiting means to insure the accurate positioning of the parts at their initial starting positions. s i

It is also contemplated that instead of actuating the transverse deforming dies by an air cylinder in one direction and a spring in the other direction, as specifically illustrated and described, or employing a driving means-therefor,

as explained in the preceding paragraph, a double acting fiuid pressure cylinder may be'ernployed to rotate the dies in opposite directions and this may be accomplished by attaching one end ofthe chain 4| (Figures 1 and 3)-to one-end of the cylinder and the other end of the chain to the other end of the cylinder, whereby-fluid pressure actuations of the cylinder in either direction will cause a corresponding movement of the dies. Or, instead of employing-the double. acting cylinder, as stated, a single acting cylinder may be employed in place of the spring v43 of the modification specifically shown and described. Thus,

it should be understood that the specific means employed to actuate the dies I6, I! is immaterial,

so far as the broader aspects of the invention are concerned.

What I claim is: a a

1. Apparatus for imparting transversely ex tending deformations in metal sheets having longitudinally extending deformations comprising in combination a pair of spaced parallel shafts,

freely rotating annular rings J'Qinnaled on said; shafts and arranged in-pairs to provide guidingj passes coincident with said longitudinal deformations, complementary deforming dies keyed to, said shafts intermediate said rings, and means to rotate said shafts in unison but in opposite directions whereby a metalsheet may be'deformed transversely while passing longitudinally between said shafts and while being guided by said rings. 2. Apparatus for imparting transversely ex tending deformations in metal sheets having lon-Z gitudinally extending deformations comprising in combination freely rotating annular rolls arranged in pairs and having complementary an-' nular surfaces to closely fit said longitudinal deformations on opposite sides of said sheets, a

pair of transversely extending carrier's positioned between said rolls and between which said sheets I are adapted to pass, complementary deforming} dies on said carriers, and means to move-said carriers in unison whereby a sheet may be deformed transversely while moving longitudinally "and while being guided by said rolls. y Y

3. In apparatus for forming'metallic surfacing sheets the combination of upper and lower shafts rotatable about spaced parallel axes and 'carrying complementary metal deforming dies extending parallel with said axes,'-'means in'terconnect-" ing said shafts whereby saidshafts rotatein unison but in opposite directions, a fluid pressure operated motor to rotate said shafts, a valve controlling the flow of fluid under pressure to'said' motor, means adapted to be engaged by the leading ends of said sheets to initiate rotation of said shafts, means responsive to said initial rotation of said shafts to open said valve, and means to control the rate of flow of fluid to said motor when said valve is in open position. 1

4. In apparatus for forming metallic surfacing sheets the combination of upper and lower shafts positioned respectively above and below the path of travel of said sheets, complementary metal deforming dies fixed on said shafts, means interconnecting said shafts whereby the shafts rotate in unison but in opposite directions, means adapted to be engaged by the leading ends of the sheets as the latter move along said path'to ini-'- tiate rotation of said shafts, a motor to rotate said shafts, and means responsive to the initial rotative movement of said shafts to energize said 

